Method of making shingle panel



F. S. BARKER METHOD OF' MAKING SHINGLE PANEL Original Filed Jan. 29,1957 Dec. zo, 1960 5 Sheets-Shea?I 1 FEA A/A/ 5, BA PL/EE F. S. BARKERMETHOD OF MAKING SHINGLE PANEL Original Filed Jan, 29, 1957 Dec. 20,1960 5 Sheets-Sheet 2 INVENTOR. PAA/e 5. BARMER WW, am 4MM Dec. 20, 1960F. s. BARKER METHOD 0F MAKING SHINGLE PANEL Original Filed Jan. 29, 19575 Sheets-Sheet 3 Dec. 20, 1960 F. s. BARKER 2,965,531

METHOD OF MAKING SHINGLE PANEL Original Filed Jan. 29, 1957 5Sheets-Sheet 4 IN V EN TOR.

FPA/VK .5. BAE/(EE BY Dec. 20, 1960 F. s. BARKER METHOD oF MAKINGSHINGLE PANEL Original Filed Jan. 29, 1957 5 Sheets-Sheet 5 IN V EN TOR.FPA/VK 5A BAE/ 66 BY @@@M/aaw MM ATTORNEYS United States Pate. O

METHOD OF MAKING SHINGLE PANEL Frank s. Barker, south Russell village,obi, assignmto Shakertown Corporation, Cleveland, Ohio, a corporation ofOhio Original application Jan. 29, 1957, Ser. No. 636,987,

now Patent No. 2,934,110, dated Apr. 26, 1960. Divided and thisapplication Dec. 18, 1957, Ser. No. 703,698

2 Claims. (Cl. 154-122) This invention relates to a method formanufacturing construction units, and more particularly to a method forsecuring shakes or shingles to a backing board.

The present application is a division of my copending application,Serial No. 636,987, filed January 29, 1957, now Patent No. 2,934,110,and entitled Apparatus for and Methods of Making Shinge Panels.

An object of the present invention is to provide a method which involvesthe removal of backing boards, one by one, from a supply source and theapplication of adhesive to selective portions of the removed backingboard; then after application of suitable shakes or shingles to saidbacking board, the advance of the construction unit to a heating unitwherein the adhesive is dried or set and the shakes or shingles becomepermanently secured to the backing board.

Another object of the invention is to provide a method in which thevarious steps of advancing the backing :board from a supply source, andapplying adhesive `strips to selective portions of the backing board,etc., are accomplished with an unusual degree of dispatch, so that lthebacking board containing adhesive strips may be further supplied withshakes, heated to dry or set the ladhesive and discharged at arelatively rapid rate as compared with existing practices.

Another object of the present invention is to provide a method formaking shingle panels which are characterized by their structuralsimplicity, the ease of assembly of their parts, their strong and sturdynature and their low manufacturing cost.

. Further objects of the present invention and certain Fig. 1 is anexploded isometric view of the'portion of :a `machine for the practiceof the present method, the machine including the feeder-conveyor and theadhesive rap'plica'ting means.

Fig. 2 is an exploded isometric `view of the machine :showing the`rotating drum and adhesive kdrying means used in producing thepresentconstruction unit.

Fig. 2A is an exploded isometric view showing the adhesive drying meansin engagement with the construction `u`nit,`in anadhesive dryingoperation.

Fig, 3 is` a side elevational view of the feeder-conveyor and-adhesiveapplicator means shown in Fig. 1.

. Fig. 4 is anend view of the drum rotatably mounted within its frame.Fig. 5 is a perspectiveviewshowing an operator placing the shakes orshingles upon the baseboard of the Prefabricated construction unit as itis held in place in thernachine.

Fig, 6 is a front perspective view of .a construction unit asmanufactured by the present machine. A

Fig. 7 is a rearperspective view of the construction unit `slniwing"themanner in `which the shakes or shingles are lattached to the baseboard.

2,965,531 ce Patented Dee. 2o, 195o Fig. 8 is an enlarged fragmentaryvertical sectional View showing a Vplurality of the construction unitsof the present invention forming the outer covering of a building wall.

Before describing in detail the herein disclosed embodi-` ment of theinvention, it is to be understood that the present invention is notlimited to the structural details or the particular `arrangement ofparts herein shown, as methods embodying the present invention may takeother forms. It also is to be understood that the phraseology andterminology herein used are for purposes of description and not oflimitation, as the scope of the present invention is denoted by theappended claims.

It is believed that a preliminary explanation of the successive steps inthe present machines` function will facilitate and expedite anunderstanding of the various macnine sections and their cooperation incarrying out the objectives of the invention.

Referring to Figs. 1 and 3, I have shown a stack of backing boards 10which are used to build the prefabricated construction units as seen inFig. 6. The backing boards, as seen in Figs. 6 and 7, are used to securea course of shingles or shakes 11 thereto in forming a prefabricatedconstruction unit or shingle panel. In operation, the machine removesthe lower backing board from the bottom of the stack 12 at the rear ofthe machine and movesy the backing board forwardly through suitablestationary feed rollers 13 and 14 to a pair of adhesive applicationrollers 15 and 16. The rollers 15 and 16 apply adhesive to the uppersurface of the backing board while it is in transit toward the frontportion of the machine wherein the shakes or shingles are appliedthereto. Following its passage under adhesive application rollers 15 and16, the` backing board travels beneath a pair of spaced adhesivespreaders 17 and 18, which are effective in smoothing out and spreadingthe adhesive strips laid down `by adhesive applying rollers 15 and 16respectively. That portion of the machine described above is enclosedwithin the housing 20, as seen in Fig. 5. Following the operationy of`spreading the adhesive strips, the backing board is presented at theleft of the operator, as seen in Fig. 5. The operator removesthe'backing boardfrom beneath the housing: 20 and places. it upon arotatable drum V21, after which he places a course of shakes or shinglesupon the adhesive containing surface of the backing board, as seen inFig. 5. Whenthe shakes have been applied to the backing board, the drum21 is rotated into theA position shown in Fig. 2a wherein the backingboard and its associated shakes are maintained in a substantiallyhorizontal position. An electrode heating press 22 is then lowered intocontact With the outer surface of the shakes and thereby dries theadhesive to form a permanent bond between the backing board and theshakes. VUpon further rotation of drum 20, a rotating saw blade 23, asseen in Fig. 2, trims the outermost edge of the shakes just prior to removal. of the construction unit from the drum 21.

Referring now to Fig. 1, wherein I have shown an isometric exploded Viewof the various essential components of the machine for purposes of moreclearly illustrating the construction of the machine and to facilitateunderstanding'the operation ofthe machine. It will,4 orfcourse,'beunderstood that the machine includes a suit.

3 ing boards in the form of a stack which rests upon a plurality oflongitudinally disposed rollers 28.

Means are provided for successively removing the backing boards from thehopper Vand transferring them forwardly of the machine. The backingboard transferring means include a feeder conveyor 30 which is slidablymounted on the machine frame and actuated by a pusher arm 31 which isconnected to feeder linkage 32, as seen in Figs. 1 and 2, and in turnactuated by clutch lever 33 as hereinafter described. When the operatorpushes clutch lever 33 the feeder linkage 32 actuates the feederconveyorin such a in'anner that the feeder-conveyor is moved under the stack ofbacking boards until the upstanding hook portions 30a provided at theend of the feeder-conveyor 30 engages the outermost end of the lowermostbacker board and moves it forwardly of the machine toward the first pairof feed rolls 13 and 14. It will be understood that as the cycle of themachine is completed, the feeder linkage 32 and its associatedfeederconveyor return to the prime position, as Ishown in Fig; 14. Theupstanding hook portions 30a have a thickness which is less than thethickness of one backing board so that no more than one backer boardwill be engaged by the hooks during a cycle of the machine. A stopbracket 26a prevents the stack of backer boards from moving forward as aunit, upon removal of the bottom board by means of the feeder-conveyor.The stationary feed rollers 13 and 14 receive the forward end of thebacking board as it is advanced by the feeder-conveyor 30 and transferit forwardly toward the adhesive applicating apparatus. The lowermostfeed roller 13 is rotatably secured beneath the guide rail 34 and isdriven by a horizontally disposed shaft 35v which is suitably journalledto the machine frame. The shaft 35 is provided with a sprocket 36 whichis driven by an endless chain 37 which in turn is driven by a suitabledrive motor hereinafter described. The uppermost roller 14 is alsodriven by means of a shaft 38 which is suitably journalled on themachine frame. Drive chain 37 engages a sprocket 39 located at the outerend of said drive shaft and thereby drives the upper roller 14. Theupper roller 14 is rotatably contained within a suitable cover 40 whichis pivotally secured by links 41 to the frame. The tension betweenrollers 13 and 14 may be controlled by the tensioning mechanism 42 whichincludes Y an adjustable compression spring 43.

A circular saw blade 44 projects upwardly through guide rail 34 to anextent wherein it provides a groove on the bottom face of the backerboard adjacent one longitudinal edge of the same as it passes thereoverand is fed forwardly through feed rollers 13 and 14 to provide abreak-off line in the backer board which aids the consumer in aligningthe panel during its installation. The saw blade 44 is driven directlyby its own motor 45.

Means are provided for coating the upper surface of the backing boardswith a pair of spaced strips of adhesive material. Said means includesthe aforementioned adhesive applying rollers 15 and 16 which aresuitably mounted so as to have a portion of their outer periphery extendinto an adhesive supply contained in an adhesive pot or container 46which is fixed to the machine frame by connecting members 47 and 48. Theadhesive applying rollers 15 and 16 are driven by means of shaft 15a anddrive pinion 15b which are driven by continuous chain 37 A stationaryfeed roller 49, driven through chain 37, pinion 49a. and shaft 49b, islocated directly beneath the adhesive application rollers 15 and 16 andaids in transferring the backing boards forwardly of the machine pastthe rollers 15 and 16. It will be noted that the adhesive container 46is substantially rectangular in shape and contains two slots to receivethe applicating rollers 15 and 16. The flow of the adhesive onto theouter periphery of the adhesive applicating rollers is regulated by wlngnuts 50 which cause members 51 to pivot about 52 and pull or push iiowregulating bars 53 to and from the outer periphery of the applicatingrollers Regulating bars 53 extend beneath the container 46 and areassociated with the adhesive applicating rollers 15 and 16 at a zonedirectly beneath the lower end of the slots in the container 46. It isto be understood that the stationary roller 49 continues to move thebacking board after it has left feed rollers 13 and 14. As the backingboard is trans-` ferred forwardly of the machine by the roller v49 it isfed onto the stationary feed roller 55 above which are mounted the twoadhesive spreader rollers 17 and 18 which are adapted to uniformlyspread the adhesive deposited by the adhesive applicating rollers 15 and16. The spreader rollers are mounted on a suitable frame 56 and 57respectively which pivot about shaft 58. Shaft 58 also contains a pairof Scrapers 59 and 60 which are adapted to keep the spreader rollers 17and 18 free from adhesive and fibers from the backing board. The shaft58 has drive pinions 61 and 62 rigidly secured thereto which are adaptedto drive the spreader rollers 17 and 18 by means of continuous chainsnot shown, which engage the pinions 63 and 64 respectively secured tosaid spreader rollers. The scrapers 59 and 60 are mounted on upstandingarms 65 and 66 which are in turn pivotally secured to shaft 58.4 Inoperation the Scrapers 59 and 60 and their associated arms are loweredinto a position wherein the outer cut; ting edges of the blade arepositioned very close to the outer periphery of the spreader rollers 17and 18 so that any excess glue or other material from the backing boardswill be immediately removed therefrom. The outer end of shaft 58 hasaffixed thereto a sprocket 67 meshing With a driven chain 68 whichpasses around a fixed sprocket 69 secured to the shaft 70 of roller 55.Shaft 70 is driven by means of endless drive chain 37` and sprocket 71.In this manner shaft 58 is continuously driven in rotation while themachine is operating and thus imparts rotative movement to the spreaderrollers 17 and 18 by the means heretofore described. After the adhesivestrips have been uniformly spread by the spreader rollers, the backingboards continue to be transferred toward the forward end of the carriageby means of stationary feed roller 55. The forward end of guide rail 34is provided with a plurality of rollers 72 which are adapted to receivethe backing boards and facilitate their removal from the guide rail 34.

A motor 73 is in driving engagement with a drive sprocket 74 which inturn drives the sprockets at the outer ends of the respective drivenmembers of the machine as heretofore described, by means of endlessdrive chain 37.

As previously mentioned, the forward end of the guide rail 34 iscontained within housing 20, as seen in Fig. 5. The operator has accessto the backing boards contained on the forward end of the guide rail viaspace 75 in the housing. Thus, as each backing board reaches the forwardend of the guide rail 34 the operator removes it therefrom and places iton the rotatable drum 21, and thereafter places a course of shakes orshingles 1l upon the top surface of the backing board, as seen in Fig.5, in bonding relation with said backing board.

Referring now to Figs. 2, 2a and 5, wherein I have shown the apparatusfor revolving the drum 21. This apparatus is contained within thehousing portion 20a as seen in Fig. 5. The drum 21 is octagonal in shapeand each face thereof is adapted to receive a backing board 10. Thebottom edge of each face is provided with a member having an upstandingfiange 76 which locates and supports the lower edges of the shakes 11.The upstanding flange portion 76 is spaced some distance below the loweredges of the backing board so that the bottom of the shakes extendsomewhat below that of the backing board 10. The driving mechanism foractuating the present machinery includes a clutch lever 80 which theoperator controls with his foot. Upon pressing the clutch downwardly, ashaft 81 is caused to rotate and thereby pivots a belt tightening boom82 which has secured thereto a cam follower 83 and cam follower arm '84which become disengaged from a notch 85a in cam 85. The belt tighteningroller 86 is pressed against belt 87 and the increased pressure ortension in the belt causes the main drive wheel 88 to be turned due tothe increased friction on the hub 89 of drive rod 90 which is connectedby means of suitable sprockets 91 and belt 92 to a driving motor, notherein shown.

The main drive wheel 88 rotates drive shaft 93 which has rigidly securedthereto a driving sprocket 94 which by means of a continuous chain 94drives a secondary sprocket gear 95 which is rigidly secured to a drivenshaft 96. The belt tightening boom 82 also operates a brake 97 whichengages main drive wheel 88. The brake 97 becomes disengaged from thedrive wheel 88 upon actuation of clutch 80. The driven shaft 96 hasrigidly secured thereto a drum activator cam 98. The drum activator cam98 is continuously driven in rotation while the drive shaft rotates. Acam follower 99 engages the periphery of drum activator cam 98 throughsuitable linkage 100` causes rotation in the drum 21. The linkage 100 isprovided with an outstanding pin 101 which engages a suitable ratchetsurface 102 provided on the inner periphery of the drum 21 in such amanner as to rotate the drum enough to present a new face during eachoperation. After the cam linkage and outstanding pin 101 have rotatedthe drum 21 through one-eighth of a circle (since the drum here isoctagonal in shape), a coil spring 103 causes the upstanding arm toreturn to the position shown in Fig. 2, wherein it is in a position tofurther actuate and rotate the drum. In other words, the upstanding pin101 forms a drum activator which rests in a notch of ratchet 102 on theinside periphery of the drum 21. When the cycle of driven shaft 96begins, the drum actually makes one-eighth of a cycle for each completecycle of shaft 96.

The electrode press 22 is positioned above the drum 21 and its purposeis to quickly dry and render the adhesive between the backing board andthe course of shakes dry and hard to thereby form a permanent bondbetween the backing board and shakes. The electrode press comprises aplurality of spaced electrodes which form pressing bars 105 which arecontained within the housing 22 and supported by suitable frame members106, shown in part in Fig. 2. The electrode press is disposed at adistance above the drum and as the drum rotates on its axis, theelectrode press is brought successively into peripheral engagement withthe outer surface of the shakes in such a manner that the electrodes orpressing bars 105 extend parallel to and in alignment with the strips ofglue contained between the backing board and the course of shakes 11.

Means are provided for raising and lowering the electrode press witheach revolution of driven shaft 96. Said means take the form of a pairof spaced cams 107 which are rigidly secured to the driven shaft 96 andengage press actuating brackets 108 which are of U-shape and aresuspended from the electrode press by means of rods 109. Each cam worksagainst a coil spring 110 which constantly urge the electrode press intoits upper position, as shown in Fig. 2. The coil springs 110 arecontained on the rods 109 by means of an enlarged end portion 109g. Therods 109 extend freely through a bracket 111 which is rigidly secured tothe frame of the machine. It will be understood that the electrode press22 has substantially the same length as the rotating drum 21 and extendsat least the full length of each of the backing boards 10 contained onthe drum 21. The outermost shake, or that which is shown at the left endof Fig. 5, is trimmed by means of saw 23 at the instant the drum 21again rotates the shake and its associated backing board following anapplication of heat from the electrode press 22. A suitable switch onthe side of the drum rotating cam trips a timer switch for a generator,not shown, which provides power for the electrodes 105 in the electrodepress 22.

The rotating saw`23 is connected to a boom 112 which raises and lowersthe saw by means of a roller cam follower 113 which engages the outerperiphery of cam 114 which is in turn rigidly secured to driven shaft96. The saw lift boom 112 is pivotally connected by means of shaft 113to the frame of the machine, not herein shown. The motor, not hereinshown, for driving saw 23 is mounted on the saw lift boom 112 andcontinuously drives the saw 23 while the machine is in operation. Avacuum funnel 114 is also mounted on the saw lift boom by suitable meansnot herein shown and moves with the saw in response to actuation by boom112.

Fig. 4 shows a somewhat diagrammatic View 0f theA means employed forrotatably mounting the drum 21 on the frame of the machine. The drum 21is supported on shaft 96 by means of a plurality of radially extendingspokes, not herein shown, which extend from the shaft 96 radiallyoutwardly and terminate around the circumference of the drum 21. Shaft96 is supported by suitable bearings 120 and 121 to the frame 122 of themachine. A housing 20a covers the drum and is secured to the frame atits lower end.

When one cycle of the machine (which is measured by a complete rotationof driven shaft 96) is completed the roller 83 on belt -tightening boom82 drops back into the notch 85a on cam 85, thus loosening belttightening roller 86 from drive belt 87 and allowing the brake 91 to beforced against the main drive wheel 88 by resilient means, not hereinshown, to stop the operation.

In further pursuance of the description of the mode of peration of thepresent apparatus, it will be understood that upon pressing the clutchlever the main drive wheel 88 is driven by means of belt 87 which isconnected to a drivingmotor, as heretofore described. The main drivewheel 88 drives shaft 93 which drives shaft 96. Upon rotation of drivenshaft 96, cam 98 causes the rotatable drum to index. Since the drum isoctagonal in shape andpreseuts eight faces, it 'will be understood thatthe drum indexes by making an eighth of a cycle for each completerotation of the driven shaft 96. As the backing board containing acourse of shakes reaches a substantially horizontal position as seen inFig. 2a, the electrode press 22 is caused to be lowered by means of cams107 mounted on driven shaft 96, as heretofore described.

During the rotative progress of the rotatable drum 21 ample time lapseswhile the backing board and its associated shakes are maintained in ahorizontal position, as seen in Fig. 2a, for the heating effect of theelectrode press to cause the desired drying of the adhesive and thelatter therefore is in suitable condition for adhesion of the course ofshakes to the backing board as already described.

The electrode press is brought successively into engagement with theouter surface of the shakes to thereby dry, through the application ofheat, the adhesive material between the backing boards 10 and the courseof shakes l1. After the press holding cams 107 allow the press holdingbrackets 108 and their associated rods 109 to rise, the drum 21 beginsto rotate or index to discharge the backing board and associated courseof shakes. As the drum indexes, the trimming saw 23 is activated by thesaw lift boom 112 into the position shown in Fig 2 wherein it trims theedge of the shakes along a desired line.

lIt will be noted that cam has connected thereto suitable linkage 116which is connected to the pusher arm 31, shown in Fig. l, which actuatesthe feeder conveyor 30. Therefore, it will be understood that uponactuation of the clutch 80 and release of the cam roller follower 83 inthe notch 85a in cam 85 the feeder linkage 32 causes a new backing boardto be moved forward by the feeder conveyor 30 into the stationary feedrollers 13 and 14 for the application of adhesive strips, as heretoforedescribed.

Thus, for each construction unit which is heated and dried by theelectrode press a new backing board is advanced to the forward end ofthe guide rail or the area adjacent the operator where he may place itupon the rotating drum 21 and proceed with another operative cycle.

The structural units manufactured by the present machine comprise abaseboard 10 in a row or course of shakes shingles 11 which are appliedto the baseboard so that the ends of the shingles project a substantialdistance beyond the upper `and lower edges of the baseboard. The ends soprojecting are arranged in a straight line as illustrated in Figs. 6 and7. The shingles 11 can be of random widths and irregular lengths, if sodesired, and each shingle is attached to the baseboard by means of theadhesive materials applied in accordance with the present invention.

In applying the multiple shingle construction units to a wall or roof130, as seen in Fig. 8, the construction units are laid up in a slightlyoverlapping relation. The baseboards 10 of the course being laid flushagainst the wall or roof surface in such a manner that the course ofshingles being laid overlap the ends of the shingles of the courseimmediately below so that the shingles of the course being laid extendover and cover the upper end of the shingles and baseboard of the lowercourse of shingles therebelow. When so arranged, the construction unitsare secured in position by the simple expedient of driving nails orother fastening means through each construction unit and into thesurface of the wall or roof. Thus, by having the baseboard secured flushto the wall or roof and the lower ends of the shingles of one courseoverlapping the top ends of the shingles of the course immediately belowa highly watertight sheathing is provided.

In view of the foregoing description, taken in conjunction With theaccompanying drawings, it is believed that a clear understanding of thepresent method will be quite apparent to those skilled in this art.

Having thus described my invention and illustrated its use, what I claimas new and desire to secure by Letters Patent is:

l. A method of making a construction unit consisting of advancing abacking board and grooving said advanc ing board on one surface thereoflongitudinally therealong closely adjacent one edge, thence applyingstrips of adhesive material to the opposite surface of said backingboard, thence spreading said adhesive strips uniformly on said oppositesurface of said backing board, thence applying a course of shingles uponsaid opposite surface of said backing board in contact with said stripsof adhesive material, thence applying heat whereby said adhesivematerial is dried and forms a bond ybetween said backing board andcourse of shingles and thence trimming the edges of said shingles.

2. A method of making a construction unit consisting of stacking aplurality of backing boards and intermittently removing one of saidbacking boards from said stack, thence grooving one surface of saidbacking board longitudinally therealong and closely adjacent one edgethereof, thence advancing said backing board and applying strips ofadhesive material to the opposite surface of said backing board, thencespreading said adhesive strips uniformly on said opposite surface ofsaid backing board, thence applying a course of shingles upon saidopposite surface of said backing board in contact with said strips ofadhesive material, thence advancing said backing board and course ofshingles to a source of heat, thence applying heat to said constructionunit whereby said adhesive material is dried and formsa permanent bondbetween said backing board and course of shingles and thence trimmingthe edges of said shingles.

References Cited in the tile of this patent UNITED STATES PATENTS 81,579Bailey Sept. 1, 1868 1,363,559 Boylan Dec. 28, 1920 1,592,760 FischerJuly 13, 1926 1,917,930 Fischer July ll, 1933 1,939,004 Fischer Dec. 12,1933 2,719,808 Elmendorf Oct. 4, 1955 2,744,046 Ware et al May 1, 1956

1. A METHOD OF MAKING A CONSTRUCTION UNIT CONSISTING OF ADVANCING ABACKING BOARD AND GROOVING SAID ADVANCING BOARD ON ONE SURFACE THEREOFLONGITUDINALLY THEREALONG CLOSELY ADJACENT ONE EDGE, THENCE APPLYINGSTRIPS OF ADHESIVE MATERIAL TO THE OPPOSITE SURFACE OF SAID BACKINGBOARD, THENCE SPREADING SAID ADHESIVE STRIPS UNIFORMLY ON SAID OPPOSITESURFACE OF SAID BACKING BOARD, THENCE APPLYING A COURSE OF SHINGLES UPONSAID OPPOSITE SURFACE OF SAID BACKING BOARD IN CONTACT WITH SAID STRIPSOF ADHESIVE MATERIAL, THENCE APPLYING HEAT WHEREBY SAID ADHESIVEMATERIAL IS DRIED AND FORMS A BOND BETWEEN SAID BACKING BOARD AND COURSEOF SHINGLES AND THENCE TRIMMING THE EDGES OF SAID SHINGLES.